Printer feeding system for elections documents

ABSTRACT

Various embodiments of a paper feed and tray extension system for adapting printer components to accommodate election document dimensions are disclosed herein. To accomplish this, a printer feed adapter system includes a paper tray extension for implementation within an existing printer that extends a paper tray to enable the paper tray to receive sheets of paper that have required dimensions for election documents. Further, paper catch extender extends a paper catch to enable the paper catch to catch election document sheets following processing by the printer.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a non-provisional application that claims benefit to U.S. Provisional Patent Application Ser. No. 63/202,007 filed May 21, 2021, which is herein incorporated by reference in its entirety.

FIELD

The present disclosure generally relates to print devices and associated components, and in particular, an improved feeding system and associated methods for printing elections documents.

BACKGROUND

Election ballot printing systems are commonly required by law to adhere to various paper and printing regulations that can be considered nonstandard for most consumer printing preferences. Thus, general printing systems that employ consumer printing devices are presently limited by the specific paper size capabilities of the off-the-shelf printer and conventional components. As such, conventional bulk printing technologies may be insufficient for mass print jobs involving elections documents.

It is with these observations in mind, among others, that various aspects of the present disclosure were conceived and developed.

SUMMARY

The following presents a simplified summary of various aspects described herein. This summary is not an extensive overview and is not intended to identify key or critical elements or to delineate the scope of the claims. The following summary merely presents some concepts in a simplified form as an introductory prelude to the more detailed description provided below. Corresponding apparatus, methods/processes, systems, and computer-readable media are also within the scope of the disclosure.

Aspects of the present inventive disclosure relate to adapting printer components to accommodate election document dimensions. To accomplish this, the present disclosure provides a printer feed adapter system that includes a paper tray extension for implementation within an existing printer that extends a paper tray to enable the paper tray to receive sheets of paper that have required dimensions for election documents. Further, the present disclosure provides a paper catch extender for implementation on the printer that extends a paper catch to enable the paper catch to catch election document sheets following processing by the printer.

In particular, aspects of the present disclosure provide: A system, comprising: a paper tray extension defining a tray extension body and configured to couple with a paper tray of a printer, the tray extension body including: a floor extension portion including a paper guide extension track that extends a paper guide track of the paper tray of the printer when coupled to the paper tray, the paper guide extension track terminating at a backstop portion of the tray extension body; an open portion defined opposite to the backstop portion that couples to a terminal edge of a tray floor of the paper tray; a first lateral extension wall that extends a first wall of the paper tray when coupled to the paper tray; and a second lateral extension wall defined opposite to the first lateral extension wall that extends a second wall of the paper tray when coupled to the paper tray; and a paper catch extension defining a catch extender body and configured to couple with a paper catch of the printer, the catch extender body including: a proximal portion defining a slot, the slot being configured to receive a distal portion of the paper catch; a distal portion defined opposite to the proximal portion, wherein the distal portion pivots outward in a paper catching position when the paper catch extension is coupled with the paper catch; and a concave surface defining an apex, wherein the apex is located at or near the distal portion of the paper catch extension. In some embodiments, the paper tray extension, when coupled with the paper tray, enables the paper tray to accommodate a sheet of paper that is at least 22 inches in length.

In one aspect, the floor extension portion of the paper tray extension is configured to interface with a paper guide of the paper tray, wherein the floor extension portion enables the paper guide to slide along the floor extension portion until the paper guide contacts the backstop portion of the paper tray extension. Further, the floor extension portion defines a floor recess having a first lateral rail, a second lateral rail defined opposite to the first lateral rail, a first medial rail and a second medial rail defined opposite to the first medial rail. The first lateral rail, the second lateral rail, the first medial rail, and the second medial rail are configured to interface with the paper guide. The open portion includes an overhang section that extends from the floor extension portion and covers a portion of the tray floor of the paper tray when coupled with the paper tray. The first lateral extension wall includes a first arm configured for insertion within a first recess of the first wall of the paper tray. Similarly, the second lateral extension wall includes a second arm configured for insertion within a second recess of the second wall of the paper tray. Further, the first arm includes an upper notch and a lower ridge that contact one or more structures within the first recess and the second arm includes an upper notch and a lower ridge that contact one or more structures within the second recess to secure the paper tray extension to the paper tray. In some embodiments, the first arm and the second arm are removably coupled to the tray extension body.

The first lateral extension wall includes a first row of ridges, wherein one or more ridges of the first row of ridges each respectively include a first flat portion that faces the open portion of the paper tray extension and a second flat portion that faces the second lateral extension wall. Further, the second lateral extension wall includes a second row of ridges, wherein one or more ridges of the second row of ridges each respectively include a first flat portion that faces the open portion of the paper tray extension and a second flat portion that faces the first lateral extension wall.

In some embodiments, with respect to the paper catch extension, the proximal portion of the paper catch extension includes a first overhang portion and a second overhang portion that contact the paper catch. The first overhang portion includes a first tapered surface and the second overhang portion includes a second tapered surface that provide a surface for a processed sheet of paper to contact as the processed sheet of paper exits an output bin of the printer. The proximal portion of the paper catch extension includes one or more side notches that enable the paper catch extension to lay flat against an output bin of the printer when the paper catch extension is not in the paper catching position.

In some embodiments, the printer feed adapter system further includes a cable support structure including a cable catch portion configured for installment along a housing of the printer.

A method of manufacture of the printer feed adapter system is further disclosed herein. In a first aspect, the method includes forming a paper tray extension defining a tray extension body, the tray extension body including: a floor extension portion including a paper guide extension track, the paper guide extension track terminating at a backstop portion of the tray extension body; an open portion defined opposite to the backstop portion; a first lateral extension wall; and a second lateral extension wall defined opposite to the first lateral extension wall. The method further includes forming a paper catch extension defining a catch extender body, the catch extender body including: a proximal portion defining a slot; a distal portion defined opposite to the proximal portion, wherein the distal portion pivots outward in a paper catching position when the paper catch extension; and a concave surface defining an apex, wherein the apex is located at or near the distal portion of the paper catch extension. In some embodiments, the method includes forming a cable support structure including a cable catch portion.

In a further aspect, the method further includes coupling the components of the printer feed adapter system to the printer. In particular, the method includes removing an original backstop of a paper tray and coupling the paper tray extension to the paper tray. The step of coupling the paper tray extension can include various sub-steps including inserting the first arm and the second arm of the paper tray extension into a first recess and a second recess of the paper tray and coupling the open portion of the paper tray extension to a tray floor of the paper tray such that an overhang section of the paper tray extension covers a portion of the tray floor. IN one aspect, the method further includes inserting the paper tray including the paper tray extension into a paper tray cavity of the printer. With respect to the paper catch extension, the method can further include coupling the paper catch extension to a distal portion of a paper catch of the printer. In a further aspect, the method can include pivoting the distal portion of the paper catch extension outward in a paper catching position. The method can also include coupling the cable support structure along a housing of the printer.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration showing a perspective view of a printer feed adapter system;

FIG. 2 is an illustration showing a paper tray of a printer;

FIG. 3A is an illustration showing a side perspective view of a paper tray extension of the printer feed adapter system of FIG. 1;

FIG. 3B is an illustration showing a top perspective view of the paper tray extension of FIG. 3A;

FIG. 3C is an illustration showing a top view of the paper tray extension of FIG. 3A;

FIG. 3D is an illustration showing an enlarged view of a ridge of the paper tray extension taken from circle 3D of FIG. 3C;

FIG. 3E is an illustration showing an enlarged view of a ridge of the paper tray extension taken from circle 3E of FIG. 3C;

FIG. 3F is an illustration showing a front view of the paper tray extension of FIG. 3A;

FIG. 3G is an illustration showing an enlarged view of a first medial rail and a second medial rail of the paper tray extension taken from circle 3G of FIG. 3F;

FIG. 3H is an illustration showing an enlarged view of a first medial rail and a second medial rail of the paper tray extension taken from circle 3H of FIG. 3C;

FIGS. 4A and 4B are a series of illustrations showing a first arm of the paper tray extension of FIGS. 3A-3H;

FIGS. 4C and 4D are a series of illustrations showing a second arm of the paper tray extension of FIGS. 3A-3H;

FIG. 5A is an illustration showing a side perspective view of an engagement of the paper tray extension of FIGS. 3A-3H coupled with the paper tray of FIG. 2;

FIG. 5B is an illustration showing a rear perspective view of an engagement of the paper tray extension of FIGS. 3A-3H coupled with the paper tray of FIG. 2;

FIG. 5C is an illustration showing a top view of an engagement of the paper tray extension of FIGS. 3A-3H coupled with the paper tray of FIG. 2;

FIG. 5D is an illustration showing a top view of the paper tray extension and paper tray of FIG. 5C including a sheet of paper;

FIG. 5E is an illustration showing a perspective view of an engagement of the paper tray extension of FIGS. 3A-3H coupled with the paper tray of FIG. 2 and inserted within a printer;

FIGS. 6A-6C are a series of illustrations showing sequential engagement of a paper catch extension of the printer feed adapter system of FIG. 1 with a paper catch of the printer of FIG. 5E;

FIG. 7A is an illustration showing a front perspective view of the paper catch extension of FIGS. 6A-6C;

FIG. 7B is an illustration showing a rear perspective view of the paper catch extension of FIGS. 6A-6C;

FIG. 7C is an illustration showing a first front view of the paper catch extension of FIGS. 6A-6C;

FIG. 7D is an illustration showing a second front view of the paper catch extension of FIGS. 6A-6C;

FIG. 7E is an illustration showing a cross-sectional view of the paper catch extension of FIGS. 6A-6C taken along line 7E-7E of FIG. 7D; and

FIG. 8 is an illustration showing a perspective view of a cable support structure of the printer feed adapter system of FIG. 1; and

FIGS. 9A and 9B are a pair of a process flows showing a method of manufacture and assembly of the printer feed adapter system of FIG. 1.

Corresponding reference characters indicate corresponding elements among the view of the drawings. The headings used in the figures do not limit the scope of the claims.

DETAILED DESCRIPTION

Various embodiments of a system and associated method for a printer feed adapter system are described herein. In particular, the printer feed adapter system is configured for placement along and/or within a printer and accommodates a larger paper size for operations including the feeding of paper into the printer through an existing paper tray and catching processed papers at an output bin. It should be appreciated that the term “feeding” includes any action for disposing paper into a printer, e.g., inputting, urging, supplying, and the like. The printer feed adapter system includes a paper tray extension that couples to the existing paper tray of the printer for feeding larger papers into the printer for processing. In some examples, the printer feed adapter system also includes a paper catch extension that envelops an existing paper catch at the output bin to accommodate larger paper documents.

Printer Feed Adapter System Overview

Printers are often used for industrial print jobs, particularly for printing ballots and other election documents that use paper having unconventional dimensions. However, it is not always cost-effective to purchase and/or design industrial printers that are specially sized for mass printing of larger documents and paper dimensions. As such, a printer feed adapter system can provide a cost-effective option for adapting a printer for mass-printing documents having unconventional dimensions.

Referring to FIG. 1, a printer feed adapter system 100 adapts a conventional printer to feed or otherwise accept and process paper of unconventional dimensions, particularly of unconventional length. The printer feed adapter system 100 includes a paper tray extension 104 that couples with an existing paper tray of a printer, enabling the printer to process large papers such as ballot documents, which often have non-standard dimensions. Further, the printer feed adapter system 100 includes a paper catch extension 102 that couples with an existing paper catch at an output bin of the printer to “catch” larger papers following processing by the printer. As shown, the printer feed adapter system 100 can also optionally include one or more cable support structures 108 for capturing one or more cables of the printer to prevent them from catching or snagging on the existing paper tray of the printer.

Paper Tray Extension

FIGS. 2-5E show a paper tray 12 of a printer 10 and the paper tray extension 104 of the printer feed adapter system 100. The paper tray 12 is configured for removable insertion within a paper tray cavity 21 of a housing 11 of the printer 10. In particular, FIG. 2 provides a perspective view of the paper tray 12 that couples with the paper tray extension 104 to enable the printer 10 to accept larger papers. The paper tray 12 notably includes a tray floor 13 with a first track 22 that couples with a first paper guide 20 and a second track 26 that couples with a second paper guide 24. The first paper guide 20 is configured to “slide” along the first track 22 to enable a user to place paper of variable length within the paper tray 12. Similarly, the second paper guide 24 is configured to “slide” along the second track 26 to enable the user to place paper of variable width within the paper tray 12. The paper tray 12 includes a drawer portion 27 that aligns with the housing 11 of the printer 10 when inserted within the paper tray cavity 21. Further, the paper tray 12 includes an original backstop 18 opposite from the drawer portion 27 that defines a maximal length of paper that can be placed within the paper tray 12. Note that the first track 22 terminates at the original backstop 18; as such, in its unmodified form, a maximal position of the first paper guide 20 is at or near the original backstop 18. As shown, the paper tray 12 includes a first wall 14 that includes a first recess 15 and a second wall 16 that includes a second recess 17. In some examples, the original backstop 18 can be removed to expose a terminal edge 19 (FIG. 5A) of the tray floor 13. The paper tray 12 includes a lifting plate 28 that lifts paper within the paper tray 12 in a vertical direction to enable one or more internal components of the printer 10 to “grab” a sheet of paper for processing.

The paper tray extension 104 is shown in FIGS. 3A-4D and is configured to couple with the paper tray 12 to enable the paper tray 12 to accept larger papers in an engagement shown in FIGS. 5A-5E. As shown, the paper tray extension 104 defines a paper tray extension body 140 having a first lateral extension wall 141 and a second lateral extension wall 145 that are each configured for respective engagement with the first wall 14 and the second wall 16 of the paper tray 12. As shown, the paper tray extension 104 provides a backstop wall 160 that replaces the original backstop 18 of the paper tray 12, and also includes an open portion 162 defined opposite to the backstop wall 160 that couples with the terminal edge 19 of the tray floor 13 of the paper tray 12. The paper tray extension 104 further includes a floor extension portion 150 that couples with the tray floor 13 and extends the first track 22 to allow the first paper guide 20 to travel along the floor extension portion 150 of the paper tray extension 104. In particular, the floor extension portion 150 has a paper guide extension track 151 that continues the first track 22 along the additional length provided by the paper tray extension 104. Further, the floor extension portion 150 includes an overhang section 148 that couples with the terminal edge 19 of the tray floor 13. In a primary embodiment, with reference to FIG. 5D, a length of the paper tray extension 104 can accommodate sheets of paper such as sheet 1 that are at least 22 inches in length, however other embodiments are also contemplated that accommodate sheets of greater or lesser length. The combined length of the paper tray 12 and the paper tray extension 104 when the paper tray extension 104 is coupled to the paper tray 12 is greater than a length of the paper tray 12 alone.

As shown in FIGS. 3A-3E and 5A-5C, the first lateral extension wall 141 includes a first arm 143 that couples with the first wall 14 of the paper tray 12, particularly with the first recess 15 of the first wall 14. Similarly, the second lateral extension wall 145 includes a second arm 147 that couples with the second wall 16 of the paper tray 12, particularly with the second recess 17 of the second wall 16. The first lateral extension wall 141 provides a first row of ridges 142 that guide paper within the paper tray 12 and prevent sheets that are “picked up” by the printer 10 from shifting out of alignment. As such, each ridge 171 of the first row of ridges 142 can be of a sawtooth shape, and can include a first flat portion 172 that faces the open portion 162 of the paper tray extension 104 and a second flat portion 173 that faces the second lateral extension wall 145. Similarly, the second lateral extension wall 145 provides a second row of ridges 146 that guide paper within the paper tray 12 and prevent sheets that the printer 10 “picks up” from shifting out of alignment Each ridge 174 of the second row of ridges 146 can be of a sawtooth shape, and can include a first flat portion 175 that faces the open portion 162 of the paper tray extension 104 and can optionally include a second flat portion 176 that faces the first lateral extension wall 141. The paper tray extension 104 prevents sheets being “dragged” by the printer 10 out of the paper tray 12 from unintentionally catching on structures by facing the first flat portion 172 of each ridge 171 of the first row of ridges 142 and the first flat portion 175 of each ridge 174 of the second row of ridges 146 towards the open portion 162 of the paper tray extension 104.

A common issue appears when printing longer sheets of paper in which when the printer 10 “catches” a sheet off the top of a stack of paper but the sheet becomes misaligned. This can be due to a lack of alignment structures within the printer 10 and/or a lack of guidance for longer sheets being taken from the paper tray 12 as they are drawn into the printer 10 for processing. This misalignment can pose an issue with longer sheets, as even a slight “tilt” or “whipping” in a side-to-side motion can become more exaggerated the longer the sheet is. Moreover, many election documents require double-sided printing on longer sheets, so this issue becomes even more apparent when the printer 10 turns the sheet over to process a second side. To remedy this problem, the first row of ridges 142 and the second row of ridges 146 can be configured to provide guidance for sheets of paper within the paper tray 12 as the printer 10 picks them up for processing. Further, when a sheet of paper is positioned within the paper tray 12, the second paper guide 24 contacts the sheet pushes the sheet towards the second wall 16. As such, the second row of ridges 146 defined along the second lateral extension wall 145 can include more ridges 174 than the first row of ridges 142 to increase an area of contact between each respective sheet and the second lateral extension wall 145; for instance, in one embodiment shown in FIGS. 3B and 3C, the first row of ridges 142 includes five ridges 171 and the second row of ridges 146 includes nine ridges 174. The “lateral-facing” edges (e.g., the second flat portion 173 of each respective ridge 171 of the first row of ridges 142 and the second flat portion 176 of each respective ridge 174 of the second row of ridges 146) keep the sheets of paper within the paper tray 12 in line. In this manner, the first row of ridges 142 and the second row of ridges 146 can be configured to guide a direction of the sheets to prevent jamming, as well as providing structural integrity points during manufacturing, particularly by a 3D printing process. The “sawtooth” configuration of the first row of ridges 142 and the second row of ridges 146 reduce an overall weight and material used for the paper tray extension 104.

As shown in FIGS. 3B and 3F-3H, the paper guide extension track 151 defines a floor recess 152 within the floor extension portion 150 that matches that of the tray floor 13 of the paper tray 12. The paper guide extension track 151 includes a first lateral rail 153 and a second lateral rail 154 defined opposite from the first lateral rail 153 that project upward from the floor recess 152 to interface with the first paper guide 20 of the paper tray 12 in an arrangement shown in FIGS. 5B and 5C. Further, the paper guide extension track 151 includes a first medial rail 155 that defines a first notched lateral side 156 and a second medial rail 157 that defines a second notched lateral side 158, the first medial rail 155 and the second medial rail 157 being configured to interface with the first paper guide 20 of the paper tray 12. The first notched lateral side 156 and the second notched lateral side 158 can collectively include a plurality of notch pairs 159 that enable the first paper guide 20 to rest at a selected position at a notch pair 159 of the plurality of notch pairs 159.

The backstop wall 160 can include a recessed portion 163 that provides a “nesting” location for the first paper guide 20 when at a maximal position along the paper guide extension track 151. The backstop wall 160 also includes a reduced height section 161 that enables the paper tray extension 104 to insert within the paper tray cavity 21 of the printer 10 without catching on various internal components of the printer 10.

With reference to FIGS. 4A and 4B, one embodiment of the first arm 143 of the first lateral extension wall 141 is shown. The first arm 143 can include an upper notch 164 and a lower ridge 165 that contact one or more structures within the first recess 15 to secure the paper tray extension 104 to the paper tray 12. The first arm 143 can be removably coupled to the paper tray extension body 140 by one or more first arm fastening elements 166. Note that the second arm 147 of the second lateral extension wall 145 is similar or otherwise identical to the first arm 143 with an exception being a direction of one or more second arm fastening elements 169. Similarly, as shown in FIGS. 4C and 4D, the second arm 147 can each include an upper notch 167 and a lower ridge 168 that contact one or more structures within the second recess 17 to secure the paper tray extension 104 to the paper tray 12. Manufacturing the first arm 143 and the second arm 147 separately from the paper tray extension body 140 can provide additional modularity to the paper tray extension 104; the first arm 143 and the second arm 147 can be removed from the paper tray extension body 140 and replaced if broken, and/or can be switched out with alternative arms to accommodate different shapes of the first recess 15 and/or the second recess 17.

Engagement of the paper tray extension 104 with the paper tray 12 is shown in FIGS. 5A-5E. As shown, the original backstop 18 (FIG. 2) of the paper tray 12 must first be removed in order to enable the paper tray 12 to receive the paper tray extension 104. The open portion 162 of the paper tray extension 104 faces the terminal edge 19 of the tray floor 13. The first lateral extension wall 141 of the paper tray extension 104 aligns with the first wall 14 of the paper tray 12 and the second lateral extension wall 145 of the paper tray extension 104 aligns with the second wall 16 of the paper tray 12. The first arm 143 of the first lateral extension wall 141 inserts within the first recess 15 of the first wall 14 and the second arm 147 of the second lateral extension wall 145 inserts within the second recess 17 of the second wall 16. The overhang section 148 of the floor extension portion 150 nests over the terminal edge 19 of the tray floor 13. When properly coupled, the floor extension portion 150 should be flush with the tray floor 13, the first lateral extension wall 141 should be flush with the first wall 14, and the second lateral extension wall 145 should be flush with the second wall 16. The paper guide extension track 151 continues the first track 22 such that the first paper guide 20 can travel along the paper guide extension track 151 as an extension of the first track 22. In the example of FIG. 5C, the first paper guide 20 is shown at an arbitrary position along the paper guide extension track 151. In the example of FIG. 5D, the first paper guide 20 is shown contacting the backstop portion 160 and nesting within the recessed portion 163 of the backstop portion.

With reference to FIG. 5E, when coupled with the printer 10, the paper tray 12 with the paper tray extension 104 can insert into the paper tray cavity 21. In some embodiments, the housing 11 of the printer 10 can include an opening (not shown) at a rear portion of the housing 11 that can enable the backstop wall 160 of the paper tray extension 104 to sit behind the housing 11 when the paper tray 12 is positioned within the paper tray cavity 21. In other embodiments, the housing 11 of the printer 10 can be cut or otherwise modified to accommodate the increased length of the paper tray 12 with the paper tray extension 104. As shown, when coupled within the paper tray cavity 21, the drawer portion 27 of the paper tray 12 can be flush with the housing 11 of the printer 10, enabling the printer 10 to capture and process individual sheets of paper from the paper tray 12.

Paper Catch Extension

Referring to FIGS. 6A-6C, the paper catch extension 102 of the printer feed adapter system 100 is configured to fit over an existing paper catch 32 of the printer 10. The paper catch 32 is positioned along an output bin 30 of the printer 10 and can seat within a paper catch recess 31. The paper catch 32 includes a proximal portion 33 pivotably coupled along the paper catch recess 31 and a distal portion 34 that extends outward and “catches” processed sheets that exit the printer 10 at the output bin 30. The paper catch extension 102 accommodates larger paper dimensions to “catch” processed sheets and keep them neatly aligned within the output bin 30; otherwise, larger sheets would fall out of the output bin 30.

With additional reference to FIGS. 7A-7E, the paper catch extension 102 includes a catch extender body 120 having a proximal portion 121 and a distal portion 128 located opposite from the proximal portion 121. The proximal portion 121 is configured to couple with the paper catch 32, and includes a slot 123 that extends into the catch extender body 120 to receive the distal portion 34 of the paper catch 32. Further, the paper catch extension 102 includes a convex surface 132 and a concave surface 134 defined opposite to the convex surface 132, where an apex 136 of the concave surface 134 is near the distal portion 128 of the paper catch extension 102. As such, when the paper catch extension 102 is coupled with the paper catch 32 and when the distal portion 34 of the paper catch is pivoted outward in a “paper catching” position shown in FIG. 6C, sheets of paper that exit the printer 10 at the output bin 30 rest along the concave surface 134 of the paper catch extension 102.

In some embodiments, the proximal portion 121 of the paper catch extension 102 includes a first overhang portion 124 defining a first tapered surface 125 and a second overhang portion 126 defining a second tapered surface 127. In particular, the first overhang portion 124 and the second overhang portion 126 each form an extension of the concave surface 134 that provide increased contact with the paper catch 32 to prevent the paper catch extension 102 from falling off of the paper catch 32. The first tapered surface 125 and the second tapered surface 127 provide a surface for a processed sheet to contact as it exits the output bin 30, and further enable the paper catch extension 102 to lay flat when not in the “paper catching” position of FIG. 6C. Further, the proximal portion 121 of the paper catch extension 102 can include one or more side notches 122 to enable the paper catch extension 102 to lay flat when not in the “paper catching” position.

Cable Support Structures

In some embodiments, the printer feed adapter system 100 can include one or more cable support structures 108 that can be installed along an interior of the housing 11 of the printer 10 to prevent USB and other cables from “catching” on various internal components of the printer 10 including the paper tray 12, with or without the paper tray extension 104. One embodiment of the cable support structure 108 is shown in FIG. 8 and includes a cable support body 180 having a planar portion 181 configured for engagement along the housing 11 of the printer 10. As shown, the planar portion 181 can include a fastening aperture 182 for receipt of a fastening element (not shown) for coupling with the housing 11 of the printer 10. The cable support body 180 includes a cable catch portion 183 that captures a cable (not shown) and secures the cable along the housing 11. One example placement of the cable support structure 108 is shown in FIG. 5E, where two cable support structures 108 are shown along the housing 11 of the printer 10, particularly above the paper tray cavity 21.

Other Embodiments and Modifications

While various embodiments of the printer feed adapter system 100 are shown with respect to one model of a printer, the printer feed adapter system 100 can be adapted to suit other models to serve the same purpose of enabling a printer to accept and process larger sheets of unconventional dimensions. In one example corresponding to the paper tray extension 104, the paper guide extension track 151 can be configured to accommodate an alternative paper guide that interfaces with an alternative paper guide track by extending any grooves, ridges, rails and/or recesses that are present within the alternative paper guide track. Further, while one embodiment described herein is configured to accommodate sheets having a length of at least 22 inches, it should be noted that the paper tray extension 104 can be configured to accommodate sheets of greater or lesser length.

METHOD

FIGS. 9A and 9B show a method 200 for forming and assembling the printer feed adapter system 100. Step 210 of method 200 includes forming a paper tray extension defining a tray extension body, the tray extension body including: a floor extension portion including a paper guide extension track, the paper guide extension track terminating at a backstop portion of the tray extension body; an open portion defined opposite to the backstop portion; a first lateral extension wall; and a second lateral extension wall defined opposite to the first lateral extension wall. Step 220 of method 200 includes forming a paper catch extension defining a catch extender body, the catch extender body including: a proximal portion defining a slot; a distal portion defined opposite to the proximal portion, wherein the distal portion pivots outward in a paper catching position when the paper catch extension; and a concave surface defining an apex, wherein the apex is located at or near the distal portion of the paper catch extension. Step 230 of method 200 includes forming a cable support structure including a cable catch portion. Steps 210-230 can be accomplished by one or more manufacture methods, including additive methods (e.g., 3D printing), reductive methods (e.g., milling), and/or molding.

Steps 240-290 detail steps of the method 200 that involve assembly of the printer feed adapter system 100 with respect to a printer such as printer 10. Step 240 includes removing an original backstop of a paper tray. Step 250 includes coupling the paper tray extension to the paper tray, and further includes sub-steps 252 and 254. Sub-step 252 includes inserting the first arm and the second arm of the paper tray extension into a first recess and a second recess of the paper tray. Sub-step 254 includes coupling the open portion of the paper tray extension to a tray floor of the paper tray such that an overhang section of the paper tray extension covers a portion of the tray floor. Step 260 includes inserting the paper tray including the paper tray extension into a paper tray cavity of the printer. Step 270 includes coupling the paper catch extension to a distal portion of a paper catch of the printer. Step 280 includes pivoting the distal portion of the paper catch extension outward in a paper catching position. Step 290 includes coupling the cable support structure along a housing of the printer.

It should be understood from the foregoing that, while particular embodiments have been illustrated and described, various modifications can be made thereto without departing from the spirit and scope of the invention as will be apparent to those skilled in the art. Such changes and modifications are within the scope and teachings of this invention as defined in the claims appended hereto. 

1. A system, comprising: a paper tray extension defining a tray extension body and configured to couple with a paper tray of a printer, the tray extension body including: a floor extension portion including a paper guide extension track that extends a paper guide track of the paper tray of the printer when coupled to the paper tray, the paper guide extension track terminating at a backstop portion of the tray extension body; an open portion defined opposite to the backstop portion that couples to a terminal edge of a tray floor of the paper tray; a first lateral extension wall that extends a first wall of the paper tray when coupled to the paper tray; and a second lateral extension wall defined opposite to the first lateral extension wall that extends a second wall of the paper tray when coupled to the paper tray; and a paper catch extension defining a catch extender body and configured to couple with a paper catch of the printer, the catch extender body including: a proximal portion defining a slot, the slot being configured to receive a distal portion of the paper catch; a distal portion defined opposite to the proximal portion, wherein the distal portion pivots outward in a paper catching position when the paper catch extension is coupled with the paper catch; and a concave surface defining an apex, wherein the apex is located at or near the distal portion of the paper catch extension.
 2. The system of claim 1, wherein the floor extension portion of the paper tray extension is configured to interface with a paper guide of the paper tray, wherein the floor extension portion enables the paper guide to slide along the floor extension portion until the paper guide contacts the backstop portion of the paper tray extension.
 3. The system of claim 2, wherein the floor extension portion defines a floor recess having a first lateral rail, a second lateral rail defined opposite to the first lateral rail, a first medial rail and a second medial rail defined opposite to the first medial rail, wherein the first lateral rail, the second lateral rail, the first medial rail, and the second medial rail are configured to interface with the paper guide.
 4. The system of claim 1, wherein the open portion includes an overhang section that extends from the floor extension portion and covers a portion of the tray floor of the paper tray when coupled with the paper tray.
 5. The system of claim 1, wherein the first lateral extension wall includes a first arm configured for insertion within a first recess of the first wall of the paper tray and wherein the second lateral extension wall includes a second arm configured for insertion within a second recess of the second wall of the paper tray.
 6. The system of claim 5, wherein the first arm includes an upper notch and a lower ridge that contact one or more structures within the first recess and wherein the second arm includes an upper notch and a lower ridge that contact one or more structures within the second recess to secure the paper tray extension to the paper tray.
 7. The system of claim 5, wherein the first arm and the second arm are removably coupled to the tray extension body.
 8. The system of claim 1, wherein the first lateral extension wall includes a first row of ridges, wherein one or more ridges of the first row of ridges each respectively include a first flat portion that faces the open portion of the paper tray extension and a second flat portion that faces the second lateral extension wall.
 9. The system of claim 1, wherein the second lateral extension wall includes a second row of ridges, wherein one or more ridges of the second row of ridges each respectively include a first flat portion that faces the open portion of the paper tray extension and a second flat portion that faces the first lateral extension wall.
 10. The system of claim 1, wherein the proximal portion of the paper catch extension includes a first overhang portion and a second overhang portion that contact the paper catch.
 11. The system of claim 10, wherein the first overhang portion includes a first tapered surface and wherein the second overhang portion includes a second tapered surface that provide a surface for a processed sheet of paper to contact as the processed sheet of paper exits an output bin of the printer.
 12. The system of claim 1, wherein the proximal portion of the paper catch extension includes one or more side notches that enable the paper catch extension to lay flat against an output bin of the printer when the paper catch extension is not in the paper catching position.
 13. The system of claim 1, further comprising a cable support structure including a cable catch portion configured for installment along a housing of the printer.
 14. The system of claim 1, wherein the paper tray extension, when coupled with the paper tray, enables the paper tray to accommodate a sheet of paper that is at least 22 inches in length.
 15. A method, comprising: forming a paper tray extension defining a tray extension body, the tray extension body including: a floor extension portion including a paper guide extension track, the paper guide extension track terminating at a backstop portion of the tray extension body; an open portion defined opposite to the backstop portion; a first lateral extension wall including a first arm; and a second lateral extension wall including a second arm defined opposite to the first lateral extension wall; and forming a paper catch extension defining a catch extender body, the catch extender body including: a proximal portion defining a slot; a distal portion defined opposite to the proximal portion, wherein the distal portion pivots outward in a paper catching position when the paper catch extension; and a concave surface defining an apex, wherein the apex is located at or near the distal portion of the paper catch extension.
 16. The method of claim 15, further comprising: inserting the first arm and the second arm of the paper tray extension into a first recess and a second recess of the paper tray.
 17. The method of claim 15, further comprising: coupling the open portion of the paper tray extension to a tray floor of the paper tray such that an overhang section of the paper tray extension covers a portion of the tray floor.
 18. The method of claim 17, further comprising: inserting the paper tray including the paper tray extension into a paper tray cavity of a printer.
 19. The method of claim 15, further comprising: coupling the paper catch extension to a distal portion of a paper catch of a printer.
 20. The method of claim 15, further comprising: forming a cable support structure including a cable catch portion. 